Manufacturing
Metal-plastic windows manufactured by OKNA SYSTEM
Since 2006, OKNA SYSTEM has been a leader in the production of metal-plastic windows and doors in Ukraine.
For window production, our company uses high-tech European equipment Fimtec (Germany) and Yilmaz (Turkey). The capacity of our equipment allows us to produce 100 metal-plastic structures per shift.
For the production of double-glazed windows, we use the European Optimac line (Turkey). This line can produce 200 double-glazed windows per shift.
The production of OKNA SYSTEM is located in 3 workshops and covers an area of 900 square meters:
1workshop
Production of metal-plastic structures
2workshop
Production of double-glazed windows
3workshop
Glazing of products. The workshop is combined with a warehouse.
Stages of window production
1
Cutting metal-plastic profiles into blanks
The production of metal-plastic windows begins with cutting a PVC profile to make a frame, window sash, and impost (window partition). The precision of cutting determines the quality of the future finished product. The cutting of blanks is carried out on a special saw. It allows cutting PVC profiles according to specified parameters with an accuracy of 0.1 mm. The exhaust device of the equipment removes chips that are formed when cutting PVC profiles.
2
Reinforcement with a reinforcing profile
The reinforcing profile is made of galvanized steel. The profile is cut according to specified parameters, after which the cut ends are subject to anti-corrosion treatment.
3
Milling drainage channels and handle holes
The drainage holes are designed to drain water from the inclined part of the frame to the street. Decompression holes are made in the upper part of the frame for air ventilation inside the air chambers. To install the handle, special holes are milled in the profile.
4
Welding of metal-plastic workpieces
The most crucial stage in the production of a metal-plastic window is welding of the blanks. Welding takes place on special equipment. Parts are attached to templates and fixed with pneumatic clamping. The workpieces are pressed against each other in the places where the parts are melted.
5
Cleaning weld seams
In the places where the elements of a metal-plastic window are welded, there are deposits that need to be removed. Welds are processed on special stripping equipment that removes the overlay from the front surfaces of the profile with special knives, and the end surface is processed with a stripping cutter.
6
Installation of the post
Install the connector of the post into the grooves of the post with 4 screws. The place of installation of the connector is sealed with silicone. To attach it to the frame, holes are drilled and special clamps are installed
7
Installation of sealing rubber
A single piece of sealing rubber is installed in the frame and sash of a metal-plastic window. The sealing rubber is glued with a molecular adhesive. A hole is additionally milled at the junction of the impost. In the upper part of the frame, holes are created at the end of the overlay and the side of the vestibule to equalize the pressure.
8
Installation of fittings
Reliable functioning of a metal-plastic window depends on the quality of installation of hardware. The installation of hardware is carried out in accordance with the design of the metal-plastic window and the package of this order.
9
Installation of sashes
Elements for fixing the sash are installed depending on the width of the sash:
upper and lower hinges and the main lock are attached to the profile of the metal-plastic window;
corner switches, upper and lower hinges, a medium-sized hinge, a narrow sash and medium locks are installed at the top and bottom of the sash.
The installation of a support for the pins eliminates sagging of the sash. The sash is attached to the frame of the metal-plastic window profile.
10
Installation of double-glazed windows
The glass unit is installed on a special glazing stand. The finished frame is attached to the stand, which fixes the metal-plastic window horizontally and vertically. Double-glazed windows are installed on special inserts and fixed with plastic wedges. A pre-prepared glazing bead is installed.
11
Adjustment of a metal-plastic window
The metal-plastic window is adjusted on a glazing stand. The product is checked for the quality of the metal-plastic window, the presence of mechanical damage and the correct functionality of the fittings.
12
Control of quality control
Finished metal-plastic windows are checked by quality control specialists, labeled and grouped by order.
Stages of production of double-glazed windows
1
Glass cutting
Glass cutting is carried out on a special glass cutting table in accordance with the parameters provided. The cutting tool of the high-tech equipment passes along the surface of the glass, on which small indentations are formed. The glass splits when it breaks along the indentation. This procedure should be done immediately after the appearance of grooves on the glass.
2
Production of distance frames and application of primary sealant
The perimeter of the spacer frame should be smaller than the perimeter of the cut glass. The prepared spacer blanks are connected with special corners and filled with absorbent using a molecular sieve filling machine. After this procedure, the cut spacer is assembled into a frame. Using an extruder, the spacer frame is coated with a primary sealant, butyl.
3
Glass cleaning
Special attention is paid to the cleanliness of the glass surface. The glass is cleaned using a six-brush washing machine. The surface of the glass must be dry and free of grease, so demineralized water is used for cleaning.
4
Assembly of a double-glazed window
During pre-assembly, the glass is connected to the spacer frame and the second pane is installed. The insulating glass unit is assembled on the insulating glass unit assembly line in a vertical position.
5
Pressing of double-glazed windows
The glass unit is pressed using a vertical press. Pressing of a double-glazed unit is intended to improve the primary sealing of the product.
6
Application of secondary sealant
For secondary sealing of a double-glazed window, a two-component sealant, polysulfide, is used. The secondary sealant is applied along the end surface of the insulating glass unit using a secondary sealing extruder.
7
Control of quality control
Finished insulating glass units are checked by the technical control service. Production tests are carried out periodically. After QC, the glass units are dried in a special room with free air circulation.